Selective Laser Sintering Printing Research Articles

Selective laser sintering at the Point-of-Care 3D printing laboratory in hospitals for cranio-maxillo-facial surgery: A further step into industrial additive manufacturing made available to clinicians

Additive manufacturing has developed rapidly in recent years and has many useful applications in the clinical field. In particular, cranio-maxillo-facial (CMF) surgery requires high precision, which can be obtained with 3D printed patient-specific surgical guides and anatomical models. Among the many different printing options, selective laser sintering (SLS) seems to be rarely used in point-of-care applications, considering its apparent characteristics.This article examines the advantages and disadvantages of SLS printers for CMF point-of-care (PoC) by reviewing the literature and comparing in-house printed SLS and stereolithography (SLA) prints.The investigation showed that the easily sterilizable and robust materials processed by SLS printing are well suited for CMF surgical guides and have clear advantages over SLA parts.Some barriers to the use of SLS printers in PoC are likely to be the slightly higher complexity and cost.However, these will decrease as 3D printing technology advances and surgeon acceptance increases, making SLS a practical PoC tool.

Influence of Build Orientation and Part Thickness on Tensile Properties of Polyamide 12 Parts Manufactured by Selective Laser Sintering.

The use of additive manufacturing to rapidly test and evaluate solutions to engineering problems has been demonstrated. Selective laser sintering (SLS) is a subset of additive manufacturing that is particularly well suited to producing structural thin wall models and end use parts which can improve the ability to prototype and manufacture certain designs at a substantially lower cost and time compared to current methods. However, a more comprehensive understanding of the material properties of these parts is warranted. The presented research investigates the influence of print orientation and sample thickness on the material properties of printed SLS parts. This novel work involves holding a hatch pattern constant across SLS prints using polyamide 12 material to isolate the anisotropic effects of orientation and thickness. An evaluation of ultimate tensile strength, modulus of elasticity, strain at failure, yield strength, and Poisson's ratio, and scanning electron microscope fractography are conducted. Transverse strain and Poisson's ratio are a key aspect that provide insight into the feasibility of building numerical orthotropic models. These data are used to calculate the degree of anisotropy due to both thickness and orientation. The results support the future use of SLS printing and modeling of thin-walled structures, such as scaled structural ship modeling. The presented data provide guidance on the impact of print orientation and thickness that will aid in manufacturing structural parts with intentionally tuned material properties.

Enhancing mechanical performance in SLS-printed PA12-slate composites through amino-silane treatment of mineral waste

The SLS additive manufacturing industry enables the development of products for diverse applications with distinct properties due to its excellent surface finish and ability to create varied part geometries, but it consumes high-performance materials with high acquisition costs. An extensive quarrying of stone leads to the accumulation of mineral residues, posing environmental hazards by contaminating soil and water when disposed of in landfills. The primary objective of the study was to incorporate mineral waste into the SLS technique and investigate the influence of its addition, along with a silane-based chemical treatment, on the mechanical performance of polymer-mineral composites (PA12-slate). Additionally, the feasibility of producing a highly loaded printed prototype, employing 50 wt% of mineral waste, was examined. Samples of PA12, PA12 blended with 50 wt% slate waste, and slate waste treated with silane underwent fabrication via selective laser sintering (SLS) and subsequent mechanical characterization, including tensile, flexural, and compressive tests. Additionally, the samples underwent accelerated aging using a QUV weathering tester, followed by mechanical characterization. The geometric accuracy, stability, and processing feasibility of these formulations were evaluated through SLS-printed composite prototypes utilizing PA12_50Sla_Si. It was found that the addition of 50% of slate to the PA12 presented mechanical properties decreasing compared to the printed PA12 only. However, an increase was verified when using silane-induced mineral bonding. The incorporation of mineral agents and silane enhanced the resistance of PA12 to aging. However, after aging, both tensile and flexural strength decreased across all printed samples. Nonetheless, this study showcased the feasibility of producing complex PA12-slate waste specimens containing up to 50 wt% of mineral waste using the SLS printing technique. Therefore, SLS presents itself as a viable means of adding value to this mineral waste.

Cold Laser Sintering of Medicines: Toward Carbon Neutral Pharmaceutical Printing.

Selective laser sintering (SLS) is an emerging three-dimensional (3D) printing technology that uses a laser to fuse powder particles together, which allows the fabrication of personalized solid dosage forms. It possesses great potential for commercial use. However, a major drawback of SLS is the need to heat the powder bed while printing; this leads to high energy consumption (and hence a large carbon footprint), which may hinder its translation to industry. In this study, the concept of cold laser sintering (CLS) is introduced. In CLS, the aim is to sinter particles without heating the powder bed, where the energy from the laser, alone, is sufficient to fuse adjacent particles. The study demonstrated that a laser power above 1.8 W was sufficient to sinter both KollicoatIR and Eudragit L100-55-based formulations at room temperature. The cold sintering printing process was found to reduce carbon emissions by 99% compared to a commercial SLS printer. The CLS printed formulations possessed characteristics comparable to those made with conventional SLS printing, including a porous microstructure, fast disintegration time, and molecular dispersion of the drug. It was also possible to achieve higher drug loadings than was possible with conventional SLS printing. Increasing the laser power from 1.8 to 3.0 W increased the flexural strength of the printed formulations from 0.6 to 1.6 MPa, concomitantly increasing the disintegration time from 5 to over 300 s. CLS appears to offer a new route to laser-sintered pharmaceuticals that minimizes impact on the environment and is fit for purpose in Industry 5.0.

Material testing for injection molded and 3D printed pristine/glass reinforced nylon at various strain rates

With the advent of new polymer material and non-conventional methods of manufacturing, the effect of loading conditions on mechanical properties has now been in huge demand to facilitate their industrial applications. Present paper has been focused on investigating the strain rate effects on mechanical properties of pristine nylon-6 and 20% glass reinforced nylon-6 material fabricated using injection molding and SLS (Selective Laser Sintering) printing manufacturing methods, respectively, at three strain rates of 0.0003, 0.003, and 0.01 per second. Tensile strength of injection molded nylon-6 has shown a positive relationship with strain rate whereas compressive strength has shown a reciprocal effect. At highest strain rate of 0.01 s−1, tensile strength exhibits 10.27% more as compared to lowest strain rate of 0.0003 s−1. Tensile strength at highest strain rate is found 60 MPa whereas at lowest strain rate it exhibits 54.41 MPa. At higher values of strain rate, rising of maximum strain is found very much sensitive than the rise in tensile strength. It also shows high percentage of deformation at higher value of strain rate. On the other hand, SLS printed 20% glass reinforced nylon-6 shows variable tensile strength with respect to strain rate due to uneven distribution of glass particles into nylon matrix created due to manufacturing process of SLS printing. FESEM images shows the cavity formation as observed before loading conditions whereas the glass fracturing phenomenon observed at the after loading conditions. However, compressive strength is found minimal with strain rate with an average value of 175.61 MPa. The findings of this study have contributed in avoiding the improper selection of material and its strain rate application during numerical modeling for industrial application purpose.

Application of Additive Manufacturing Technology for Chair Parts Connections

Additive manufacturing (AM) is a potential technology to be applied for replacing wood joints in the furniture industry. Overall, 3D-printed connectors have a lot of advantages in chair construction: the possibility of improving the design by using colored materials and new concepts with no limits of shape and size, avoiding the use of synthetic materials such as adhesives and finishing materials. The present research shows the results of the research conducted on 3D-printed connectors for a chair leg-stretchers joint. Larch (Larix decidua Mill.) wood was used for chair components and selective laser sintering (SLS) technology was employed for the 3D-printing connector designed to assemble the chair elements. Diagonal tensile and compression tests were performed on the L-type joints with 3D-printed connectors and the bending moments were determined and compared to the results obtained after testing the leg-stretchers mortise–tenon joints made of larch wood, taken as a reference. Micrograph investigation was finally performed on the broken areas of the 3D-printed connectors as a result of mechanical testing failures. The results show that the SLS printing technology applied to build the connector does not ensure enough strength to the assembly, and changes in printing parameters are needed for further research, in terms of laser power and scan speed.

Preparation and Characterization of 3D-Printed Dose-Flexible Printlets of Tenofovir Disoproxil Fumarate.

The aim of this work was to design pediatric-friendly, dose-flexible orally disintegrating drug delivery systems (printlets) of the antiviral drug tenofovir disoproxil fumarate (TDF) by selective laser sintering (SLS) for potential use in hospitals along with other antiviral drugs. In order to obtain a consistent quality of printlets with desired properties, it is important to understand certain critical quality attributes for their main and interactions effect. The printlets were optimized by Box-Behnken's design of the experiment by varying process variables while keeping the composition constant. The composition contained 16.3% TDF, 72.7% polyvinyl pyrrolidone K16-18, 8% magnesium aluminum silicate, 3% Candurin® NXT Ruby Red, and 0.3% colloidal silicon dioxide. The process variables studied were surface (X1), chamber temperatures (X2), and laser scanning speed (X3). The range of variable levels was 75-85°C for X1, 50-70°C for X2, and 200-240 mm/s for X3, respectively. The responses studied were hardness, disintegration time, dissolution, physiochemical, and pharmacokinetic characterization. X-ray powder diffraction indicated partial or complete conversion of the crystalline drug into amorphous form in the printlets. Comparative pharmacokinetics between Viread® (generic) and printlets in rats were superimposable. Pharmacokinetic parameters showed statistically insignificant differences between the two formulations in terms of Tmax, Cmax, and AUC of (p > 0.05). Printlets were bioequivalent to Viread® as per FDA bioequivalence criteria. Thus, the SLS printing method showed the fabrication of dose-flexible printlets with quality, and in vivo performance equivalent to commercial tablets.

Additive manufacturing of flame retardant polyamide 12 with high mechanical properties from regenerated powder

PurposeThis paper aims to develop flame-retardant (FR) polyamide 12 (PA12) nanocomposite from regenerated powder via selective laser sintering (SLS), an additive manufacturing technique.Design/methodology/approachFirst, the morphology, processibility, thermal and mechanical properties of PA12 regenerated powder, consisting of 50 wt% new and 50 wt% recycled powder, as well as corresponding printed specimens, were evaluated to characterize the effects of previous SLS processing. Second, flame-retardant PA12 was developed by incorporating both single and binary halogen-free flame retardants into the regenerated powder.FindingsIt was found that the printed specimens from regenerated powder had much higher tensile and impact properties compared to specimens made from new powder, which is attributed to better particulate fusion and coalescence realized in higher temperature SLS printing. The effect of FRs on thermal, mechanical and flame retardant properties of the PA12 composites/nanocomposites was investigated systematically. It was found that the nanoclay, as a synergist, improved both flame-retardant and mechanical properties of PA12. UL94 standard rating of V-0 was achieved for the printed nanocomposite by incorporating 1 wt% nanoclay into 15 wt% phosphinates FR. Moreover, on average, the tensile and impact strength of the nanocomposite were increased by 26.13% and 17.09%, respectively, in XY, YZ and Z printing orientations as compared to the equivalent flame retardant composite with 20 wt% of the phosphinates FR.Originality/valueThis paper fulfills the need to develop flame retardant parts via SLS technology with waste feedstock. It also addresses the challenge of developing flame retardant materials without obviously compromising the mechanical properties by making use of the synergistic effect of nanoclay and organic phosphinates.

Investigating the Use of Magnetic Nanoparticles As Alternative Sintering Agents in Selective Laser Sintering (SLS) 3D Printing of Oral Tablets.

Selective laser sintering (SLS) is a single-step, three-dimensional printing (3DP) process that is gaining momentum in the manufacturing of pharmaceutical dosage forms. It also offers opportunities for manufacturing various pharmaceutical dosage forms with a wide array of drug delivery systems. This research aimed to introduce carbonyl iron as a multifunctional magnetic and heat conductive ingredient for the fabrication of oral tablets containing isoniazid, a model antitubercular drug, via SLS 3DP process. Furthermore, the effects of magnetic iron particles on the drug release from the SLS printed tablets under a specially designed magnetic field was studied. Optimization of tablet quality was performed by adjusting SLS printing parameters. The independent factors studied were laser scanning speed, hatching space, and surface/chamber temperature. The responses measured were printed tablets' weight, hardness, disintegration time, and dissolution performance. It has been observed that, for the drug formulation with carbonyl iron, due to its inherent thermal conductivity, sintering tablets required relatively lower laser energy input to form the tablets of the same quality attributes as the other batches that contained no magnetic particles. Also, printed tablets with carbonyl iron released 25% more drugs under a magnetic field than those without it. It can be claimed that magnetic nanoparticles appear as an alternative conductive material to facilitate the sintering process during SLS 3DP of dosage forms.

Preparation of high-porosity biomass-based carbon electrodes by selective laser sintering

Selective-laser-sintering (SLS) three-dimensional (3D) printing technology was used to fabricate highly porous biomass-based carbon electrodes, which were prepared using pine wood powder mixed with phenolic resin as the SLS printing material. The pinewood powder content in the mixture was varied from 30 to 50 wt% to find the correlation between pinewood content and electrical conductivity and mechanical properties. The 3D-printed precursors were carbonized in a tubular sintering furnace to finally obtain SLS biomass porous carbon electrodes. The physical properties, microstructure, pore distribution, and electrical conductivity of the printed porous carbon electrodes were investigated by scanning electron microscopy, X-ray diffraction, and electrical conductivity tests. The results indicate that highly customized carbon electrodes with high porosity can be fabricated using pine composites in combination with the SLS 3D printing process.

On the Reuse of SLS Polyamide 12 Powder.

In the Selective Laser Sintering (SLS) technique, the great majority of the powder involved is not included in the final printed parts, being just used as a support material. However, the quality of this powder is negatively affected during the process since it is subjected to high temperatures (close to its melting temperature) during a long time, i.e., the printing cycle time, especially in the neighborhood of the printed part contour. This type of powder is relatively expensive and large amounts of used powder result after each printing cycle. The present paper focuses on the reuse of Polyamide 12 (PA 12) powder. For this sake, the same PA 12 powder was used in consecutive printing cycles. After each cycle, the remaining non-used powder was milled and filtered before subsequent use. Properties of the powder and corresponding prints were characterized in each cycle, using differential scanning calorimetry (DSC), scanning electron microscopy (SEM), computed tomography (CT), and tensile tests. It was concluded that subjecting the same powder to multiple SLS printing cycles affects the properties of the printed parts essentially regarding their morphology (voids content), mechanical properties reproducibility, and aesthetical aspect. However, post-processing treatment of the powder enabled to maintain the mechanical performance of the prints during the first six printing cycles without the need to add virgin powder.

Development of Composite, Reinforced, Highly Drug-Loaded Pharmaceutical Printlets Manufactured by Selective Laser Sintering-In Search of Relevant Excipients for Pharmaceutical 3D Printing.

3D printing by selective laser sintering (SLS) of high-dose drug delivery systems using pure brittle crystalline active pharmaceutical ingredients (API) is possible but impractical. Currently used pharmaceutical grade excipients, including polymers, are primarily designed for powder compression, ensuring good mechanical properties. Using these excipients for SLS usually leads to poor mechanical properties of printed tablets (printlets). Composite printlets consisting of sintered carbon-stained polyamide (PA12) and metronidazole (Met) were manufactured by SLS to overcome the issue. The printlets were characterized using DSC and IR spectroscopy together with an assessment of mechanical properties. Functional properties of the printlets, i.e., drug release in USP3 and USP4 apparatus together with flotation assessment, were evaluated. The printlets contained 80 to 90% of Met (therapeutic dose ca. 600 mg), had hardness above 40 N (comparable with compressed tablets) and were of good quality with internal porous structure, which assured flotation. The thermal stability of the composite material and the identity of its constituents were confirmed. Elastic PA12 mesh maintained the shape and structure of the printlets during drug dissolution and flotation. Laser speed and the addition of an osmotic agent in low content influenced drug release virtually not changing composition of the printlet; time to release 80% of Met varied from 0.5 to 5 h. Composite printlets consisting of elastic insoluble PA12 mesh filled with high content of crystalline Met were manufactured by 3D SLS printing. Dissolution modification by the addition of an osmotic agent was demonstrated. The study shows the need to define the requirements for excipients dedicated to 3D printing and to search for appropriate materials for this purpose.

Systematic Literature Review on Methodology and Manufacturing Process of Personalized Tablet using Selective Laser Sintering Technology

3-dimensional printing (3DP) technology has garnered interests as a novel candidate for future pharmaceutical manufacturing. Since the first drug product (Spritam®) has been approved for commercialization by the Food and Drug Administration (FDA), there has been an enormous opportunity for printing custom drugs using 3DP. Many 3DP methods have been documented for pharmaceutical applications in the literature. However, selective laser sintering (SLS) printing remains the least studied for pharmaceutical applications. There are many advantages and challenges in adopting an SLS method to fabricate personalized medicines, such as accurate, cheaper, and simpler ways to configure dosing for certain patient groups. In this study, we systematically reviewed all available literature investigating the technique of personalized printlets using SLS printing, and further discussed the method used in its process. A systematic searching strategy was performed in Scopus, PubMed, and Google Scholar databases using predetermined search strings. Of the 122 articles, only eight articles completely met the inclusion criteria, and they were subsequently used for data synthesis. The results showed that the printing process, spectrophotometry analysis, thermal analysis, X-ray powder diffraction and characterization of the printlet were the vital parameters in the printing method, leading to potential pharmaceutical applications in personalized medicine.

Novel High-Speed 3D Printing Method Using Selective Oil Sintering with Thermoplastic Polyurethane Powder Printing.

Present methods used in three-dimensional (3D) printing, such as selective laser sintering (SLS) and multijet fusion (MJF), have limited applications, especially in relation to the manufacturing of biomedical products. The speed of SLS printing is too low, and high-speed 3D printing technology with MJF uses carbon black particles as a fusing agent, which cannot be removed from the completed 3D printed products. Carbon black and high-energy lasers are not suitable for biomedical applications, especially human implants. A new high-speed 3D method is therefore required. In this study, we used hot oil droplets (175°C) as a new type of fusing agent to melt the biomaterial thermoplastic polyurethane (TPU) powder particles to define the print area. This method replaces lasers and the carbon black fusing agent in high-speed 3D printing technology and is more energy efficient. In addition, this method can be used to not only print on TPU, but also on other flexible materials.

Evaluating poly(ether ether ketone) powder recyclability for selective laser sintering applications

Poly(ether ether ketone) (PEEK) is increasingly used in selective laser sintering (SLS) due to its superior mechanical and thermal properties and biocompatibility. It is well known that the properties of selective laser sintering (SLS) powder govern the processability and quality of the parts. The SLS printing process exposes the PEEK bed/feedstock to variable elevated temperatures (above 300 °C) for a prolonged time. The effect of this thermal history on the part quality is unknown. This work evaluates the changes that occur in thermally treated PEEK powder through spectroscopic, morphological, and rheological characterizations. It was found that crystallinity increased marginally within the first two hours, but particle size and shape remained virtually unchanged. The thermal treatment also resulted in a significant increase in the melt viscosity of the PEEK powder, and its flowability slightly improved. Understanding these changes could help to reduce waste through recycling of some portion of PEEK powders used in SLS printing.

Study of a polymer ejector design and manufacturing approach for a mobile air conditioning

• Design and manufacturing approach of a polymer ejector for a mobile air conditioning. • Selection of suitable materials for the application with the refrigerant R1234yf. • FEM analyzes of the ejector design under the conditions of a refrigeration cycle. • Experimental comparison of a steel and a polymer ejector. Polymer ejectors manufactured with injection molding offer a low cost and lightweight design for automotive applications compared to traditional metal designs. New materials need to be resistant against the refrigerant R1234yf and withstand the pressure under operating conditions of a mobile air conditioning. In this paper, a material research selects possible material candidates for a polymer ejector. A FEM simulation investigates the stability and deformation of the ejector when using a polymer material instead of the usual stainless steel solution. A selective laser sintering (SLS) printed polyamide 12 ejector is benchmarked in an enhanced vapor-compression refrigeration cycle against a stainless steel prototype on a test bench. Both ejectors implement the expected pressure levels and show a good pressure recovery rate. However, the new polyamide 12 ejector has a faster decrease of performance from its maximum efficiency. The difference in the ejector performance is expected to be caused by a larger manufacturing tolerance in the SLS printing, leading to a larger nozzle diameter. The design of a polymer ejector is successfully tested, offering new applications for the ejector technology in the automotive industry.

Oral preparations with tunable dissolution behavior based on selective laser sintering technique.

Selective laser sintering (SLS) sinters a powder layer by layer with a laser beam to prepare 3D printlets, which are widely used in the field of tissue engineering and personalized implants. To promote the SLS printing of oral solid preparations, the printability of commonly used drugs and excipients was evaluated using a 450nm low energy laser. It was found that yellow drugs could absorb laser energy and sinter, while white drugs and pharmaceutical excipients had SLS printability when tartrazine lake was added as a photoabsorber. The printing mechanism of non-crystalline and crystalline polymers was powder sintering and powder melting, respectively. Increasing the laser energy density was beneficial to the printing efficiency but reduced printing accuracy. To ensure the integrity of multilayer printlets, the sintered thickness of each layer should be greater than the layer thickness. Furthermore, ibuprofen immediate-release tablets and metoprolol tartrate sustained-release tablets were prepared. Using 10% carboxy methyl starch sodium as an additive, the shell tablets with a side thickness of 1.5mm had a good appearance and fast dissolution. Based on the optimized formulation, IBU preparations with various design shown good appearance and fast release property. There was no difference in the drug's crystalline state after SLS printing. Besides, the printed reservoir tablets with a sustained-released coating thickness of 3.5mm had a good appearance and allowed 12h sustained release. The results revealed that the SLS technique has great prospects in producing personalized oral preparations with immediate-release and sustained-release properties.

Build orientation effects on mechanical properties and porosity of polyamide-11 fabricated via multi jet fusion

Abstract The HP Multi Jet Fusion (MJF) technology is a relatively recent addition to powder bed fusion additive manufacturing techniques. It differs from selective laser sintering (SLS) technology through the use of fusing and detailing agents to control part geometry, and the use of a planar infra-red radiation (IR) source, which sweeps over the powder bed, to initiate the sintering process. The results in this study suggest that the MJF-fabricated polyamide-11 (PA11) parts showed very low porosity of less than 1%, but different amounts depending on the build orientation. Our study also indicates that there is significant build orientation-dependent anisotropy in the mechanical properties, which are correlated to the porosity in the parts. We also found that the specimens oriented at a 45° angle relative to the build platform consistently performed the best in terms of tensile mechanical properties by simultaneously avoiding the negative influences of poor intra-layer powder packing in the horizontal plane (observed in the horizontally-oriented specimens) and the orientation of the inter-layer interface against the load direction (observed in the vertically-oriented specimens). The strategies usually adopted in SLS printing by aligning the build orientation of parts to the direction of the tensile loads for improved Young’s modulus and/or tensile strength seem not to be applicable for MJF-fabricated PA11 parts.

Indirect selective laser sintering-printed microporous biphasic calcium phosphate scaffold promotes endogenous bone regeneration via activation of ERK1/2 signaling

The fabrication technique determines the physicochemical and biological properties of scaffolds, including the porosity, mechanical strength, osteoconductivity, and bone regenerative potential. Biphasic calcium phosphate (BCP)-based scaffolds are superior in bone tissue engineering due to their suitable physicochemical and biological properties. We developed an indirect selective laser sintering (SLS) printing strategy to fabricate 3D microporous BCP scaffolds for bone tissue engineering purposes. The green part of the BCP scaffold was fabricated by SLS at a relevant low temperature in the presence of epoxy resin (EP), and the remaining EP was decomposed and eliminated by a subsequent sintering process to obtain the microporous BCP scaffolds. Physicochemical properties, cell adhesion, biocompatibility, in vitro osteogenic potential, and rabbit critical-size cranial bone defect healing potential of the scaffolds were extensively evaluated. This indirect SLS printing eliminated the drawbacks of conventional direct SLS printing at high working temperatures, i.e. wavy deformation of the scaffold, hydroxyapatite decomposition, and conversion of β-tricalcium phosphate (TCP) to α-TCP. Among the scaffolds printed with various binder ratios (by weight) of BCP and EP, the scaffold with 50/50 binder ratio (S4) showed the highest mechanical strength and porosity with the smallest pore size. Scaffold S4 showed the highest effect on osteogenic differentiation of precursor cells in vitro, and this effect was ERK1/2 signaling-dependent. Scaffold S4 robustly promoted precursor cell homing, endogenous bone regeneration, and vascularization in rabbit critical-size cranial defects. In conclusion, BCP scaffolds fabricated by indirect SLS printing maintain the physicochemical properties of BCP and possess the capacity to recruit host precursor cells to the defect site and promote endogenous bone regeneration possibly via the activation of ERK1/2 signaling.

Study on optimization of PES/CaCO3 composite powder for selective laser sintering (SLS) 3D printing technology

In this study, a new type of friendly environment material including polyether sulphone resin powder (PES), and limestone flour (CaCO3) (referred to as CO-PES-CaC) has been developed for selective laser sintering (SLS) additive manufacturing that is low cost, environmentally friendly and energy efficient. The aims of this study were to optimization of PES/CaCO3 composite powder for SLS printing technology. The mechanical properties and microstructure of CO-PES-CaC affected by different the ratio of PES powder and CaCO3 powder has been studied. The experimental results indicate that the CO-PES-CaC quality was optimum when the ratio of PES powder and CaCO3 powder was 75/25. The mechanical properties peak at 8.09 MPa for tensile strength and 15.28 MPa for flexural strength, and 3.91 kJ/m2 for impact strength.